brc76
RR Helper
Posts: 1,107 
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Apr 30, 2015 18:21:18 GMT
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Not lost your sanity, just misplaced it at the right time
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Finally someone who's not doubting my sanity  With the sore back getting better, I was hoping to move forward today. Started by removing the exhaust and prop shaft...  The exhaust holder is of a much better design - just another thing that got improved from the W124 era. Next was to unbolt the gearbox and all it's connections - which are onl three; wiring loom, shift rod and shift lock cable. I hope I can somehow delete the latter, it's anoying as fcuk.    ^the wiring loom plug of course was full of oil - a known issue with those gearboxes. There's a leak-stopp adapter avaiölable which is like 11€. The TCU will probably be full of oil too. Which is no issue as long as there are no metal shavings in the oil (the wiring loom soaks with oil and capilary forces draw it into the TCU). Speaking of the TCU; all the electronic magic is contained in a box - the main engine loom is just two plugs and the engine can be removed. Very convenient!  Then I stripped the ancilliaries of the engine, to make life a little easyer for my knackered old engine hoist...  Nice bonus: 115 amp alternator  I was planing to upgrade this anyway, no need to buy one  and then came the big moment... Did I forgett something? Will it move? Will the engine hoist cope?   Hooray! It did! Removed from it's rusty prison after all Surprisingly, the five speed automatic is not as huge as I thought it is. I don't think it's much longer than the old 4 speed...  Anyway - I got much more done today than I expected - the heavy stuff is done - now there's only a couple of wires left to free from the car. Har har.  Cheers, Jan |
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Mark
Club Retro Rides Member
Posts: 2,097
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Jan, There may be an alternative to the special gearbox controller - I think if you can replicate a lot of the inputs i.e. add wheel speed sensors etc then you could use original gearbox ECU |
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That's worth examining 'Cause I think the aftermarket TCUs don't reduce torque during shifts. Which apparently helps the 5G-Tronic to stay alive. I recently drove a W210 E200 (gas) and it was almost like an automated manual, with every shift RPM dropped and rose again when the gear was engaged - weird The OM606 doesn't do this (luckily as I might add!), so I guess the wastegate is briefly opened on the diesel? Anyway, for now I'M using the electronics for both engine & transmission - they come for free with the car and work very well. EGR & MAF can be deleted, all I need to know is how to get rid of the shift-lock mechanismn. I think that's a rather annoying thing... Cheers, Jan |
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krazy kraut keep it up |
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2001 HONDA CT110 (NOT RCV)
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I have been looking at your thread for awhile now and I'm glad that finally you've gone to the right engine conversion!...:-) I'm planning on going that route myself when my Volvo 760 d24Tic goes south (knock wood)
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Had a couple of hours today to start stripping the wiring... Awefull work, boring and tedious. The worst part of the whole thing, and the most time consuming.  Also started to strip out the interior, to gain access to all the wiring looms runing through the car...  ...for example to the shifter; which also contains electronics.  Once the carpet & dashboard are out it'll be "easy" to remove all the wiring looms. What makes it double annoying is the fact that this car is build very differently to previous cars; W108, W115, W123, W124, W201 - they all are build similar-ish. This W210 - nope. It's all designed so it can be quickly assembled on the conveyor belt... Sigh. Cheers, Jan |
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that this car is build very differently to previous cars; W108, W115, W123, W124, W201 - they all are build similar-ish. This W210 - nope. It's all designed so it can be quickly assembled on the conveyor belt... Sigh. I think you've nailed it there, it's what everyone says about these later M-B products. |
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I'm starting to get a bit dizzy in my head Might be a copper worm infection? I don't know... I've touched a lot of unprotected wires lately. It would all be simple - but mr. stressed worker on assembly line just randomly stuffed wires in, next random conveyor belt worker put a carpet on top - hey presto! All done with the premium best-or-nothing Mercedes. Sigh... Most "looms" are entangled and meshed together - pure CHAOS. Still, I made a lot of progress today. Extracting the gearbox wiring loom which runs across the whole car. I removed the carpet & dashboar prior to opening the wiring channels. I'll let the pictures do the talking here...       And of course the TCU is filled with oil  But since it was still working well, I assume it's not damaged. I'll let it drain, give it a clean and invest a couple of bucks in a oil-stopp cable. Well it might appear like nothing has happened, but now I know the basic wiring setup of the gearbox, know where everything is running to and what's connected to what and how. I labeled all up, tidied and split the loose wires into actuall wiring looms - not it can be extracted from the car next. The more time I'm taking with this now, the less time it'll take to install everything later. I'm starting to get a feel why mechanicall pumps & gearboxes are such a popular choice Cheers, Jan |
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omg wires where dafuq do you start ein bischen bier fur dich I'm (curse word you spellchecker) juli |
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Last Edit: May 5, 2015 17:45:07 GMT by hairnet
2001 HONDA CT110 (NOT RCV)
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Gimme hop, joana... Er - hope. Guess what? Another day of - wires... But: I fully separated the gearbox & engine wiring loom, found the CAN connection and freed up the diagnostics socket. Diving deep into the fuse/relais box...  Unwrapped and split the main engine room wiring looms (horns, AC, headlights, washer - all runing in one loom) and isolated it.  And here'S another example of what makes this job so annoying; crossed wires. Which means: go back a couple of meter of raveld wires, figure out what does what, try to unknot them and then decide to cut it and hpe for the best. This is very time consuming.  But I'm rather double-cautios now then scratching my head later when it comes to make it all work again. At least I got the wiring loom for the oil cooler fans out; no electronics! Just a simple relais, two temperature switches and two fans. Easy. But awefully wired, I actually had to cut 2 wires to get it out. And moving a bit towards the Coupé; I think I can find a convenient space for the throttle sensor here. Warm and dry. It's one ofthe most important sensors in the whole car.  On a side-note: the cruise-controll is allready part of the ECU and std. equipment. And even better: the switch fits the steering column shrouds from '93 on Bonus: limiter function. Nice! I'm seeing light at the end of the tunnel, finally! But there's still a complete loom I need to unwrap... Cheers, Jan |
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gn3dr
Part of things
Posts: 391
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I hope you are keeping a note of all the wiring colours needed so that I can lazily copy it when I get around to doing mine. |
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Fantastic as always. Look forward to watching the progress.
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 1965 Mk1 Mini 1989 Porsche 911 3.2 Carrera Sport 2004 Audi A2 TDi 2007 Lotus Exige S 2011 Mini Cooper SD |
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All by hand Speaking of which: one ASR & gearbox wiring loom out...  Need to split them later, but should be easy. And shortly followed by the engine wiring loom.   Stored in the Coupé's boot for now. Next was the removal of the oil coolers. Sadly both fans are stuck and very hard to turn. I don't think I'm making use of them.  And of course - there's more wires Need to figure out the starting circuit, then the car can go to the scrappy. Only need to remove steering rack & 4 doors and it's done.  Put the bumper back on and made use of the empty engine bay, tyres are sold and will go soon. Storeage room's tight, though  Also pulled the front brake calipers to put on some 15" scrapp wheels to keep it rolling. Cheers, Jan |
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All that wiring  makes me want to hide in a dark room crying like a little girl  Look forward to more progress though, well done. |
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Me too, me too!!! But then who'd stripp it all out? Right now I'm not very confident this all will work like I want it to! |
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May 11, 2015 13:08:33 GMT
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Jan,
Great progress, much respect deserved for going down this route! I can see that there's a lot of potential in this engine compared to the old idi as much as the old one is great. Can't wait to see it finished.
By the way, some of your photos seem to have been doing a bit of a shuffle.
Rich
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May 12, 2015 10:41:01 GMT
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Not yet! It's not yet done and I don't know if it can be done (by me that is ). I have also contacted "my" pump builder and the guy making the aftermarket TCU (which could also controll a VTG turbocharger...). This would solve many problems, but cost a lot more money. As it stands now, a ECU und TCU came with the car allready - for free. I just don't know yet if it will work. Some say it will, some say it will not. I will try - but purely for economics. I think a mech. pump would be far more reliable. I don't know. I've not yet done my final decision (as allways  . Btw; the W204 C-class intercooler I bought last year is actually bigger than the W210 intercooler! But not wider (a bit shorter in fact)...   If I can get this to fit, should be a nice upgrade! Cheers, Jan |
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May 14, 2015 15:03:08 GMT
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Damn, that's a sweet ride. I also have a 1991 300CE OM603 diesel. Also, what's your cars color code? It seems like that's an unique color, never seen anything like this before.
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1991 300CE Diesel.
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I was planing to upgrade this anyway, no need to buy one 
makes me want to hide in a dark room crying like a little girl 
.